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Special Instruction
Procedure to Properly Grease Hydraulic Hammers{6333}
Media Number -REHS1368-01 Publication Date -20/04/2006 Date Updated -20/04/2006 i02534090

Procedure to Properly Grease Hydraulic Hammers{6333}


SMCS - 6333-086-U51 Hydraulic Hammer: H45/H45s (S/N: 6CZ1-UP) H50/H50s (S/N: 5MZ1 -UP) H35Ds (S/N: BXH1-UP) H55Ds (S/N: BWM1-UP) H65Ds (S/N: BYT1 -UP) H63/H63s (S/N: 4GL1-UP) H70/H70s (S/N: 4KL1-UP) H90C/H90Cs (S/N: 6TZ1-UP) H100/H100s (S/N: 4ML1 -UP) H115/H115s (S/N: 4PL1-UP) 120/H120Cs (S/N: 9MM1-UP) 130/H130s (S/N: 7CM1-UP) 140/H140s (S/N: 4SL1-UP) H140Cs (S/N: BED1 -UP) H140Ds (S/N: BXB1 -UP) 160/H160s (S/N: 4TL1-UP) H160Cs (S/N: BFB1 -UP) H160Ds (S/N: BXF1 -UP) 180/H180s (S/N: 9PM1-UP)

Introduction
This Special Instruction describes the process of properly lubricating your hydraulic hammer. Improper lubrication of a hydraulic hammer may result in premature failure of the lower piston seal and damage to both piston and cylinder.

Illustration 1 Seal extrusion failure due to over greasing

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Illustration 2 Piston failure from extruded seal

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ReferenceCaterpillar Failure Analysis Guide, SEBF8892

Benefits of Proper Lubrication


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Lower owning and operating costs Reduced tool and bushing wear Increased production Reduced down time

Operation and Maintenance Support Media


Product support information is available to reinforce the proper lubrication procedure. Caterpillar Impact Products Limited strongly recommends the following information to be used in order to help prevent premature failures from improper lubrication. ReferenceOperation and Maintenance Booklet, HEPU9000, This booklet illustrates the correct and incorrect methods of operation and maintenance of hydraulic hammers. This booklet can be placed in the cab of any host machine for the operator's reference. ReferenceCaterpillar Hammer Operation and Maintenance Video, TMRV5390, This video (CD) demonstrates correct operation techniques and maintenance procedures. English, French, German, Italian, Portuguese and Spanish versions of the video are contained on the CD. A CD is provided with every new hammer shipped. ReferenceMachine Window Decal, SMEU7397, The decal illustrates the correct and incorrect methods of

operation and maintenance of hydraulic hammers. The decal can be applied to the window inside the cab of the host machine for the operator to reference. ReferenceOperation and Maintenance Manual, SEBU7345, Operation and Maintenance Manual, SEBU7921, Operation and Maintenance Manual, SEBU7346, Operation and Maintenance Manual, SEBU7382, All Operation and Maintenance Manuals for hydraulic hammers contain information, illustrations, and pictures that demonstrate the correct and incorrect methods of operation and maintenance for hydraulic hammers. An Operation and Maintenance Manual is delivered with each new hydraulic hammer that is shipped to a dealer.

Equipment Requirements
Table 1 Required Tools Item (1) (2) Qty 1 1 Pt. No. 8F-9866 130-6951 Part Name Grease Gun Caterpillar Hammer Paste

Lubrication Procedure

Illustration 3

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This is the location of the piston and the tool during greasing. (A) Piston (B) Tool Point

(C) Tool Bushing

1. Apply pressure to the tip of the hammer tool so that the tool is in contact with the piston. 2. Shut off the machine.

NOTICE
Failure to apply down pressure on the hammer tool during lubrication could result in piston seal failure. This seal failure will allow oil to leak from the hammer tool. To avoid seal damage, always apply down pressure on the hammer tool during lubrication.

Illustration 4 g00908558 Hammer in a vertical position on level ground with down force applied to the hammer.

3. Orient the hammer in a vertical position.

Illustration 5 Typical example

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4. Locate the lubrication points. Note: There is one grease fitting on the H35Ds, H45, H45s, H55Ds, H65Ds, H140Cs and H160Cs. There are two grease fittings on the H50, H50s, 63, H63, H63s, 70, 70s, H70, H70s, H90C, H90Cs, 100, 100s, H100, H100s, H115s, H120Cs, H130s, H140Ds, H160Ds and the H180s.

Illustration 6 Decal

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Note: The fittings have been marked with the decal that is shown in illustration 6. 5. Apply 10 to 15 strokes from the grease gun to the tool bushings and the hammer tool. Caterpillar Impact Products Limited strongly recommends the use of 130-6951 Caterpillar Hammer Paste for all applications on the hydraulic hammers. Refer to the Operation and Maintenance Manual, "Lubricating Grease" for more information. 6. If the hammer is equipped with an automatic lubrication system, check the hammer tool for a collar of grease. The collar of grease must be completely around the hammer tool. If the collar of grease is too large or the collar of grease is too small, refer to the Service Manual, "Testing and Adjusting" for

information about setting the timer. Refer to the Operation and Maintenance Manual, "Automatic Lubrication" for more information on the automatic lubrication system.

Results of Incorrect Greasing

Illustration 7 Seal Failure

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Illustration 8 Seal Failure

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Proper down force must be used in order to bring the piston in contact with the tool during greasing. If the piston is not in contact with the tool, premature seal failure will result. With the seal failure, damage to the piston and the cylinder will occur.

Tool Failures Caused by Lack of Grease

Illustration 9 Improper greasing will cause failures in these areas.

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Seizures occur as the tool slides over the bushing with no lubrication. Seizures are caused by the following conditions:
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The working angle is incorrect. There is insufficient grease. Single spot operation beyond 15 second interval The wrong type of grease is used. The interval between greasing is incorrect. Incorrect Autolube setting for hammer size The Autolube is out of grease. The Autolube is not working properly.

Illustration 10 Failure types.

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Illustration 11

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Illustration 12

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The failure of a tool can result from a concentration of stress once a crack is formed.

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Tue Aug 26 07:05:51 UTC+1200 2008

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